Engines Citroen BERLINGO 2004 1.G Workshop Manual

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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1EP1E3D
Rotate the engine to drive it in its normal direction of rotation.
Peg the flywheel at
«b». using tool [1].
Move aside the harness
(7).
Remove:
The engine support
(8).
The screw
(10).
The accessories drive pulley
(9).
The lower timing cover
(11).
The upper timing cov
(12).
The tool
[1].
B1BP305C
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1EP1E6D
Refit the screw (10).
Turn the crankshaft to bring the camshaft towards its pegging point.
Peg the camshaft at
«c», using tool [2](oil the pegs).WARNING: Do not press or damage the track of the engine speed sensor target
(13).
Peg the crankshaft at «e», using tool [3].
Remove:
The timing belt protector
(13).
The engine speed sensor (14).
Slacken the screw (15)of the tensioner roller, and keep it slackened using an allen
spanner at «d».
Detension the timing belt by pivoting the tensioner roller (clockwise).
Remove the timing belt, starting with the coolant pump pinion.
Checks.
ESSENTIAL: Just prior to refitting, proceed to the checks as below.
Check:
That the rollers and the coolant pump pulley turn freely (without play and without tight
spot).
That there are no signs of oil leaks (at the crankshaft and camshaft seals).
That there are no leaks of coolant fluid(at the coolant pump).
That the track of the engine speed sensor target (15)is not damaged or scratched.
Replace any components that are defective (if necessary).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1EP1E7D
Refitting.
Fit the timing belt on the crankshaft pinion.
Position the belt on the guide roller, belt well tensioned.
Refit:
The timing belt protector
(13).
The engine speed sensor
(14).
Reposition the timing belt, strip
«f»well tensioned, in the following sequence:
Guide roller
(16).
Camshaft pulley
(20).
Fuel high pressure pump pulley
(19).
Coolant pump pulley
(17).
Tensioner roller
(18).
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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
B1EP1E8C
Adjusting the timing belt tension.
Act on the tensioner roller (18)to align the marks «g»and «h», avoiding detensioning the
timing belt, using an allen spanner at «d».
Should this fail, repeat the operation to tension the timing belt.Hold the tensioner roller
(18).
Tighten the tensioner roller fixing nut to 3,7 ± 0,3 m.daN.
Check the position of the tensioner roller (the alignment of the marks «g»and «h»should
be correct).
Remove tools [2]and [3].
Rotate the crankshaft six times(clockwise).
IMPERATIVE:Never rotate the engine backwards.
WARNING:
Do not touch or damage the track of the target of the engine speed sensor (14).
Peg the crankshaft, using tool
[3].
Check the position of the tensioner roller (the alignment of the marks «g»and «h»should
be correct).
If this is not the case, repeat the operation to tension the timing belt.
Peg the camshaft pulley, using tool
[2].
IMPERATIVE: Should it be impossible to peg the camshaft, check that the offset bet
ween the camshaft hole and the pegging hole is not more than 1 mm. If the offset is
too great, repeat the operation.
Remove tools [2]and [3].
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: 9HZ 9HY
Refitting (continued).
Refit tool [1]at «b».
Remove the screw (10).
Refit:
The upper timing cover
(12).
The lower timing cover (11).
The accessories drive pulley (9).
The screw (10).
Tightening torqueScrew (10)Pretighten to:3 ± 0,3 m.daN.
Angular tighten:180°±5°.
Remove tool [1].
Refit:
The engine support
(8), tighten to5,5 ± 0,4 m.daN.
The engine support (4), tighten to 6,1 ±0,6 m.daN.
The engine support (5), tighten to 2,5 ±0,2 m.daN.
The electrical harness (7).
The power steering fluid reservoir (6).
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Disengage the jack from under the engine.
Couple:
The tube
(2).
The exhaust line, tighten the clip to 2,5 ± 0,3 m.daN.
The fuel unions (1).
The air/air heat exchanger inlet and outlet pipes (3).
Connect the connector at «a».
Refit:
The accessories drive belt
(see corresponding operation).
The front RH splashshield (see corresponding operation).
The front RH wheel, tighten to 9 ± 1 m.daN.
Reconnect the positive and negative terminals of the battery.
IMPERATIVE: Perform the operations that are necessary following a
reconnection of the battery (see corresponding operation).

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ENGINE
(1) «Idler»camshaft pulley(2)Target for cylinder reference sensor.(3)Camshaft hub.(4)«Fixed»crankshaft pinion.
The determining of the tension of the timing belt is done on the cam
shaft pulley
(1).
The new timing on 8 valveengines DW10TD (RHY)and DW10
ATED (RHS-RHZ)requires the following components:«Idler»crankshaft pinion«Fixed»camshaft pulley.
(5) «Fixed»pulley with integral cylinder reference
sensor target).(6) «Idler»crankshaft pinion (with increased width keyway groove).
The determining of the tension of the timing belt is done on the crankshaft pinion
(6).
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
OLD FITTING:# N° RPO 9127 NEW FITTING N° RPO 9128 #
B1EP176DB1EP177D
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ENGINE
The new fitting discontinues the following components:
Camshaft hub.
Cylinder reference sensor target.
Repair – Accessories drive pulley
Remove – Refit
WARNING:
Peg the camshaft and the crankshaft before ever removing the
accessories drive pulley (the pegging prevents any offsetting of the camshaft).
If necessary, apply a paint spot to mark the accessories drive pulley being
replaced.
Replacement parts.
The Replacement Parts service markets the old as well as the new components.
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
NEW FITTING N° RPO 9128 # (Continued)
B1EP177D
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ENGINECHECKING AND SETTING THE VALVE TIMING
NOTE: Checking and setting the valve timing on engines: RHYRHZ N° ⁄ RPO 9127
See Mechanic’s Handbook 2003: pages 193 to196
Tools.
[1]
Belt tension measuring equipment :4122T
[2]
Tension lever:().0188.J2
[3]
Engine flywheel peg: ().0188.Y
[4]
Belt clamp: ().0188.AD
[5]
Camshaft pulley peg: ().0188.M
[6]
Engine flywheel lock: ().0188.F
[7]
Set of blocking plugs:().0188.T
[8]
Pulley extractor:().0188.P
[9]
2 mm dia.peg: ().0188.Q2Removing.
IMPERATIVE: Respect the safety and cleanliness requirements
that are specific to high pressure diesel injection (HDi) engines.
Undo the front RH wheel bolts.
Raise and support the vehicle on the front RH side.
Disconnect the battery negative terminal.
Remove:
The underengine sounddeadening.
The front RH wheel.
The front RH splashshield. The engine cover.
Unclip and move aside the cooling hose.
Remove the accessories drive belt
(see corresponding operation).
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Engines: RHY RHZ N° RPO 9128 #

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ENGINE
CHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Uncouple, plug and move aside, using tool [7], the fuel delivery pipe (2)and return
pipe (1).
Remove:
Screws
(3), (4) and (6).
Screw (7).
The upper timing cover (5).
WARNING:Refit screw (7)equipped with a spacer (17 mm thick), tighten the
screw (7)to 1,5 ± 0,1 m. daN.
NOTE:The screw (7)is one of the screws securing the coolant pump and is there
for its sealing.
Put the gear lever in 5th gear.Turn the road wheel to turn the engine in its direction of rotation.
Orient the camshaft pulley in the pegging position, use a mirror if necessary.
Peg the camshaft, using tool
[5].
Peg the engine flywheel, using tool
[3].
B1EP1A7CB1BP2H3CB1BP2H2CB1BP2R2C
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ENGINECHECKING AND SETTING THE VALVE TIMING
Engines: RHY RHZ N° RPO 9128 #
Remove:
The fixings of the pipe linking the power steering pump with the rotary valve.
The clutch lower closing plate.
Lock the engine flywheel, using tool
[6].
Remove the screw (8).
Refit the screw (8)without its thrust washer.
Remove:
The accessories pulley
(9), using tool[8].
Tool [6].
The lower torque reaction rod.
Support the engine by means of a workshop hoist.
Remove:
The bearing shell fitting
(10).
The nut (12).
Screws (11).
The bracket (13).
NOTE:Lift then lower the engine with the workshop hoist, to have access to the
timing cover fixing screws.
Remove:
The intermediate timing cover.
The lower timing cover.
B1CP04BCB1BP2R3CB1BP2R4C
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